|Project by Andy||posted 06-23-2015 03:56 AM||2298 views||34 times favorited||13 comments|
I’m posting this at the request of several members who commented on my Greene and Greene Desk.
I’ve tried William Ng’s method for making plug and I found it quite time consuming and I was never really happy with the results. The method also limits you by the size of your drill chuck. I also tried the jig that Darrell Peart uses in one of his books but I couldn’t ever get great results. Obviously he has had lots of practices and gets amazing results. Maybe someday I will try it again.
I purchased William Ng's fingernail bit made by Whiteside for routing splines. While building my desk I wondered if I could route the end grain of a piece of ebony gasp. If I had a jig with a radius that matched the radius on the bit I would have a perfectly symetrical plug so I decided to give it a shot. I built the jig, marked the radius of the bit and then sanded to the radius. The bearing on the bit follows the radius giving my a perfectly cut plug.
The picture shows the jig that resulted from this crazy idea. The jig has a small insert that houses the ebony stick quite tightly to eliminate any tearout. I clamp it all down and route off as little as possible and end up with a very clean finish. I finish it up with some sanding at 600 grit followed by a couple seconds on the buffing wheel to give me a nice polished finished. By the way you can very quickly route the ends of both sticks or multiple sticks to improve efficiency.
Please comment below and let me know what you think. Any ideas for improvements or do you think I’m crazy?